2005-2006 Honda ATV TRX500FE/FM/TM FourTrax Foreman Factory Service Manual, Page 154Get this manual
CYLINDERPISTON
SERVICE INFORMATION
GENERAL
The cylinder and piston can be serviced with the engine installed in the frame Take care not to damage the cylinder wall and piston Be careful not to damage the mating surfaces when removing the cylinderDo not strike the cylinder too hard during removal Rocker arm and valve lubricating oil is fed through the oil passage in the cylinderClean the oil passage before installing the cylinder
SPECIFICATIONS
Unit: mm (in)
ITEM I.DOut-of-round Taper Warpage Piston, Piston O.Dat 15 (0.6) from bottom piston pin, Piston pin hole I.Dpiston ring Piston pin O.DPiston-to-piston pin clearance Piston ring end gap Top Second Oil (side rail) Piston ring-to-ring Top groove clearance Second Cylinder-to-piston clearance Connecting rod small end I.DConnecting rod-to-piston pin clearance Cylinder STANDARD 92.00092.010 (3.62203.3.6224) 91.96591.985 (3.62073.6214) 20.00220.008 (0.78750.7877) 19.99420.000 (0.78720.7874) 0.0020.014 (0.00010.0006) 0.15-0.30(0.006-0.012) 0.30-0.45(0.012-0.018) 0.20-0.70(0.008-0.028) 0.0300.060 (0.00120.0024) 0.0300.060 (0.00120.0024) 0.0150.045 (0.00060.0018) 20.02020.041 (0.78820.7890) 0.0200.047 (0.00080.0019) SERVICE LIMIT 92.10 (3.3.626) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) 91.93 (3.619) 20.04 (0.789) 19.96 (0.786) 0.08 (0.003) 0.5 (0.02) 0.6(0.02) 0.09 (0.004) 0.09 (0.004) 0.10 (0.004) 20.07 (0.790) 0.10 (0.004)